CN110940373A - Reation kettle fault alarm system based on mobile terminal - Google Patents
Reation kettle fault alarm system based on mobile terminal Download PDFInfo
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- CN110940373A CN110940373A CN201910583086.8A CN201910583086A CN110940373A CN 110940373 A CN110940373 A CN 110940373A CN 201910583086 A CN201910583086 A CN 201910583086A CN 110940373 A CN110940373 A CN 110940373A
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- 238000006243 chemical reaction Methods 0.000 claims abstract description 45
- 238000012545 processing Methods 0.000 claims abstract description 25
- 238000004519 manufacturing process Methods 0.000 claims abstract description 11
- 238000003745 diagnosis Methods 0.000 claims abstract 2
- 238000012544 monitoring process Methods 0.000 claims description 7
- 230000006870 function Effects 0.000 claims description 6
- 230000002159 abnormal effect Effects 0.000 claims description 5
- 239000003638 chemical reducing agent Substances 0.000 claims description 4
- 238000007405 data analysis Methods 0.000 claims description 3
- 238000013480 data collection Methods 0.000 claims description 3
- 230000008878 coupling Effects 0.000 claims description 2
- 238000010168 coupling process Methods 0.000 claims description 2
- 238000005859 coupling reaction Methods 0.000 claims description 2
- 238000013500 data storage Methods 0.000 claims description 2
- 230000005484 gravity Effects 0.000 claims 3
- 238000004080 punching Methods 0.000 claims 1
- 238000005070 sampling Methods 0.000 claims 1
- 238000000034 method Methods 0.000 abstract description 3
- 230000008569 process Effects 0.000 abstract description 2
- 238000011156 evaluation Methods 0.000 abstract 1
- 238000001914 filtration Methods 0.000 abstract 1
- 230000008054 signal transmission Effects 0.000 abstract 1
- 238000004458 analytical method Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000005540 biological transmission Effects 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000009991 scouring Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 238000003860 storage Methods 0.000 description 2
- 230000001133 acceleration Effects 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 238000003889 chemical engineering Methods 0.000 description 1
- -1 chemical engineering Substances 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 239000002360 explosive Substances 0.000 description 1
- 238000005984 hydrogenation reaction Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 230000003993 interaction Effects 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 238000010295 mobile communication Methods 0.000 description 1
- 238000006396 nitration reaction Methods 0.000 description 1
- 239000000575 pesticide Substances 0.000 description 1
- 239000003208 petroleum Substances 0.000 description 1
- 231100000572 poisoning Toxicity 0.000 description 1
- 230000000607 poisoning effect Effects 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 231100000331 toxic Toxicity 0.000 description 1
- 230000002588 toxic effect Effects 0.000 description 1
- 238000004073 vulcanization Methods 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01D—MEASURING NOT SPECIALLY ADAPTED FOR A SPECIFIC VARIABLE; ARRANGEMENTS FOR MEASURING TWO OR MORE VARIABLES NOT COVERED IN A SINGLE OTHER SUBCLASS; TARIFF METERING APPARATUS; MEASURING OR TESTING NOT OTHERWISE PROVIDED FOR
- G01D21/00—Measuring or testing not otherwise provided for
- G01D21/02—Measuring two or more variables by means not covered by a single other subclass
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- G—PHYSICS
- G08—SIGNALLING
- G08C—TRANSMISSION SYSTEMS FOR MEASURED VALUES, CONTROL OR SIMILAR SIGNALS
- G08C17/00—Arrangements for transmitting signals characterised by the use of a wireless electrical link
- G08C17/02—Arrangements for transmitting signals characterised by the use of a wireless electrical link using a radio link
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- Arrangements For Transmission Of Measured Signals (AREA)
Abstract
The invention discloses a reaction kettle fault alarm system based on a mobile terminal. The working condition of the reaction kettle is monitored by collecting, transmitting, analyzing, storing and displaying fault signals. The method comprises the steps of firstly collecting pressure, vibration and temperature signals of a reaction kettle during working through a high-performance sensor, then transmitting the signals to a high-performance data acquisition card through a signal transmission module, carrying out processing such as filtering conversion on the collected signals by using the acquisition card, then transmitting the processed signals to an industrial personal computer, processing original waveforms through virtual instrument software in the industrial personal computer, then uploading fault diagnosis evaluation parameters processed by the software to a server, connecting the server through a mobile terminal such as a mobile phone and the like, and displaying the parameters on a user interface of an application program in real time. And when the equipment fails, an alarm is given out, so that a worker is reminded to process in time. Effectively avoid the production accident because of reation kettle trouble production, improve the safe production coefficient.
Description
Technical Field
The invention relates to a container state monitoring system, in particular to a reaction kettle fault alarm system based on a mobile terminal.
Background
As the process industrial device is developing towards large-scale and high-parameter direction, the reaction kettle serving as a common industrial reaction vessel is widely applied to various industries such as petroleum, chemical engineering, rubber, pesticide, pharmacy, food and the like. The reactor is mainly used for completing vulcanization, nitration and hydrogenation and is used as a key container working at high temperature and high pressure for a long time, and the potential risk of accidents caused by failure of a reaction kettle is increased day by day.
In the continuous production of modern chemical enterprises, the reaction kettle is affected by factors such as medium corrosion, scouring, over-temperature and over-pressure, equipment vibration and the like, and the problem of leakage can be inevitably caused. The reaction kettle can not work normally due to the vibration failure of the speed reducer and the coupling, and the failure of the reaction kettle is very easily caused due to the abnormal pressure caused by the reasons of the processing size error of the sealing surface, the aging of the sealing element, the improper installation and fastening and the like.
If the problem of failure of the reaction kettle cannot be timely solved, the leakage can be rapidly enlarged under the scouring of the medium, the loss of the material is caused, and the production environment is damaged, so that the shutdown and production halt of enterprises are caused, and huge economic loss is caused. If toxic, harmful, flammable and explosive media are leaked, serious accidents such as personnel poisoning, fire hazard and explosion can be caused.
The mobile terminal or called mobile communication terminal refers to a computer device which can be used in mobile, and broadly includes a mobile phone, a notebook, a tablet computer, a POS machine, and even a vehicle-mounted computer. But most often refer to cell phones or smart phones and tablets with multiple application functions.
Disclosure of Invention
The invention aims to provide a reaction kettle fault alarm system of a mobile terminal. The current situation that the working state of the industrial reaction kettle needs to be monitored frequently and manually is improved. Realize that the staff uses handheld mobile terminal equipment, through the wireless transmission mode, the real-time data collection that the server that comes from the monitoring area sent is received in the continuation of anytime and anywhere to carry out the analysis work of storage and data to the data of gathering, send the police dispatch newspaper when data are unusual, make the staff know the operating condition of reation kettle anytime and anywhere to some extent, realized long-range real-time supervision, avoid can't in time handle when reation kettle breaks down, can effectively promote production factor of safety.
The purpose of the invention is realized by the following specific technical scheme: the invention comprises a pressure sensor, a temperature sensor, a vibration sensor, a signal processing device, a power supply, an industrial control host, a data center server, a mobile terminal and other equipment. The signal processing device consists of a constant current adapter, a multifunctional USB acquisition module and a data acquisition card, is powered by a power supply, and is used for carrying out real-time monitoring and early warning by measuring temperature, vibration and pressure signals of the reaction kettle, converting and processing the signals, uploading the signals to a server through a wireless communication network, transmitting the signals to a mobile terminal, and transmitting the signals to a remote monitoring host through the Internet.
The functions of the components of the invention are as follows:
(1) a sensor portion: the system mainly comprises a high-performance pressure sensor, a temperature sensor and a vibration sensor, and is responsible for collecting and guiding parameters on the reaction kettle into a signal processing device.
(2) The signal processing apparatus section: the wireless sensor network consists of a constant current adapter, a multifunctional USB acquisition module and a data acquisition card, and converts analog signals collected by a sensor part into digital signals and sends the digital signals to a wireless network.
(3) Power supply: power is supplied to the sensor section and the signal processing apparatus section.
(4) An industrial control host: and receiving the processed digital signals, receiving the digital signals through an Ethernet interface module, processing the digital signals through virtual instrument software in the host, and storing the digital signals by using an SQL (structured query language) database.
(5) A data center server: the data processing and interaction tasks of the mobile terminal and the data acquisition terminal are mainly realized.
(6) A mobile terminal: and receiving the data from the signal receiving device, comparing and analyzing the data with normal data, and giving an alarm in time when receiving abnormal data to remind a worker to maintain.
The specific function realization of the invention not only needs the support of the hardware, but also needs the processing and analysis of the related virtual instrument software to realize the accurate detection of the state of the reaction kettle and the timely early warning when the fault occurs. The software part relates to the following specific functions:
(1) data acquisition and storage: the digital signals collected by the hardware are collected into a software module and stored so as to be convenient to call.
(2) Displaying an interface: and displaying the acquired pressure, temperature and acceleration signals in real time, and observing the state of the reaction kettle in time.
(3) Analysis of the data: and collecting data collected in a short time to judge whether the reaction kettle works normally or not.
(4) And (4) alarm processing: and if the reaction kettle does not work normally after data analysis, an alarm is sent out in time, and abnormal data is displayed and stored to remind workers and find problems in time.
The invention has the advantages that the invention has no similar type, when the reaction kettle is invalid or even before the reaction kettle is invalid, the system data and the warning line are compared, and when the data exceeds the warning line, an alarm is sent out to remind the working personnel to take measures in time, so that the loss and the production accidents are avoided.
The invention has the advantages and effects that:
the invention utilizes the pressure, temperature and vibration sensors and the wireless communication network to monitor the state of the reaction kettle in real time, and the data of the sensors are uploaded to the data center server after being processed and then are monitored by the mobile equipment, so that the workers can realize remote real-time monitoring on the reaction kettle at any time and any place, the original manual frequent inspection is replaced, the labor and time are saved, the constraint of the working place on the workers is eliminated, the loss and production accidents caused by the failure of the reaction kettle are avoided, the safety production coefficient is improved, and the enterprise loss is effectively reduced.
Drawings
FIG. 1 is a diagram of a sensor position assembly of the present invention
FIG. 2 is a schematic diagram of the operation of the signal processing unit
FIG. 3 is a diagram of a data transmission structure according to the present invention
The specific implementation mode is as follows:
the present invention will be specifically described with reference to fig. 1 and 2.
2. The reaction kettle fault alarm system based on the mobile terminal as claimed in claim 1, wherein the pressure sensor (1) is embedded in the kettle body through a hole, the temperature sensor (2) is installed on the surface of the upper end socket of the reaction kettle, and the vibration sensor (3) is respectively adsorbed on the speed reducer and the coupler.
3. The mobile terminal-based reaction kettle fault alarm system as claimed in claim 1, wherein the signal processing device is composed of a constant current adapter, a multifunctional USB collection module and a data collection card, and the receiving device converts the collected analog signals into digital signals, transmits the digital signals to a data center server through a wireless network, and then receives the data through a mobile device for monitoring.
4. The mobile terminal based reactor fault alarm system of claim 1, wherein the mobile device software implements functions including data acquisition, data storage, interface display, data analysis, and alarm processing.
5. The mobile terminal-based reaction kettle fault alarm system is implemented according to claim 1, wherein real-time pressure, temperature and vibration signals generated during the operation of the reaction kettle are collected by a sensor to a signal processing device, the collected analog signals are converted into digital signals and are uploaded to a server through an industrial control host, and the digital signals are transmitted to the server and then analyzed and monitored through mobile equipment, so that an alarm is given when the reaction kettle is in an abnormal condition, and workers are timely reminded.
According to the invention, because the pressure born by the reaction kettle in the production process is higher, a pressure sensor needs to be installed to monitor the pressure condition born by the reaction kettle in time, holes are punched in the kettle body according to needs, the pressure sensor (1) is embedded, and the surface temperature of the reaction kettle is measured by using the armored temperature sensor, so that the temperature sensor (2) is installed on the surface of the upper end socket of the reaction kettle, and the vibration sensor (3) is respectively adsorbed on the speed reducer and the coupler. The mounting position is shown in fig. 1.
Real-time pressure that reation kettle's during operation produced, the temperature, the analog signal that signal processing device will collect by the sensor converts digital signal into and uploads the server through the industrial control host computer to the vibration signal, upload behind the data center server rethread mobile device and monitor data, will pass through in the signal collection APP software module of processing on mobile terminal, by the working condition that shows interface real-time display reation kettle, thereby in time send out the police dispatch newspaper when finding data anomaly and remind the staff, concrete flow is as shown in fig. 2.
Claims (10)
1. The utility model provides a reation kettle fault alarm system based on mobile terminal which characterized in that, the system includes equipment such as pressure sensor (1), temperature sensor (2), vibration sensor (3), signal processing device, power, industrial control host computer, data center server, mobile terminal and constitutes.
2. The reaction kettle fault alarm system based on the mobile terminal as claimed in claim 1, wherein the pressure sensor (1) is embedded in the kettle body through punching, the temperature sensor (2) is installed on the surface of the upper end socket of the reaction kettle, the vibration sensor (3) is respectively adsorbed on the speed reducer and the coupling, the fault diagnosis parameters can be calculated by virtual instrument software on the industrial control host after the signals collected from the sensor are processed by the signal processing device, and then the parameters are uploaded to the server and monitored by receiving the server data on the mobile terminal in real time.
3. The mobile terminal based reaction kettle fault alarm system as claimed in claim 1, wherein the signal processing device is composed of a constant current adapter, a multifunctional USB collection module and a data collection card.
4. The mobile terminal based reactor fault alarm system of claim 1, wherein the data acquisition card is a USB-4702 acquisition card.
5. The mobile terminal-based reaction kettle fault alarm system as claimed in claim 1, wherein the multifunctional USB acquisition module adopts MHBI1138D multifunctional hybrid acquisition module.
6. The mobile terminal-based reaction kettle fault alarm system of claim 1, wherein the mobile device software realizes functions including data acquisition, data storage, interface display, data analysis and alarm processing, and the receiving device converts the collected analog signals into digital signals, transmits the digital signals to the data center server through a wireless network, and then receives the data through the mobile device for monitoring.
7. The mobile terminal based reaction kettle fault alarm system as claimed in claim 1, wherein the collected original waveform is converted into fault parameter indexes such as form factor, margin index, center of gravity frequency and the like in an industrial personal computer through virtual instrument software LabVIEW.
Form factor:
margin indexes are as follows:
center of gravity frequency:
wherein
Where Δ is the sampling interval.
8. The mobile terminal based reaction kettle fault alarm system of claim 1, wherein when fault parameter indexes such as form factor, margin index, center of gravity frequency and the like exceed a warning value, the mobile terminal sends out an alarm to remind a worker to remove the fault.
9. The mobile terminal based reaction kettle fault alarm system of claim 1, wherein real-time pressure, temperature and vibration signals generated during the operation of the reaction kettle are collected by a sensor to a signal processing device, the collected analog signals are converted into digital signals and are uploaded to a server through an industrial control host, the digital signals are transmitted to the server and then analyzed and monitored through mobile equipment, and an alarm is given when the reaction kettle is in an abnormal state, so that staff can be reminded in time.
10. The reation kettle fault alarm system based on mobile terminal can realize that the staff can know reation kettle's operating condition anytime and anywhere, realize long-range real-time supervision, avoid unable timely processing when reation kettle breaks down, can effectively promote production factor of safety.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
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| CN201910583086.8A CN110940373A (en) | 2019-07-01 | 2019-07-01 | Reation kettle fault alarm system based on mobile terminal |
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| CN201910583086.8A CN110940373A (en) | 2019-07-01 | 2019-07-01 | Reation kettle fault alarm system based on mobile terminal |
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN111879540A (en) * | 2020-07-14 | 2020-11-03 | 上海数深智能科技有限公司 | Method for monitoring deflection degree of stirrer of glass lining reaction kettle |
| CN115687984A (en) * | 2023-01-05 | 2023-02-03 | 绍兴市特种设备检测院 | Method for monitoring health state of stirring kettle |
| CN115903632A (en) * | 2022-12-30 | 2023-04-04 | 广东石油化工学院 | A system and method for multi-sensor data acquisition and abnormal change alarm of a reactor |
| CN119086130A (en) * | 2024-09-09 | 2024-12-06 | 东莞鸿威润滑油有限公司 | A method for testing the low temperature resistance of perfluoropolyether preparation equipment |
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